Lennox PWC183, PWC18E4.8, PWC18E9.2, PWC242, PWC18E10.7 Installation And Maintenance Instructions Manual

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INSTALLATION AND

MAINTENANCE INSTRUCTIONS

PWC Series "Magic-Pak"

Self-Contained Heat Pump

[ WARNING

Improper installation, adjustment, alteration, service or maintenance can cause injury

or property damage. Refer to this manual. For assistance or additional information,

consult a qualified installer or service agency.

I _'WARNING I

For your safety, do not store or use gasoline or other flammable vapors and liquids in the

vicinity of this or any other appliance. Such

actions could result in property damage, per- sonal injury or death.

Installation and servicing of air conditioning equipment can be hazardous due to internal

refrigerant pressure and live electrical compo- nents. Only trained and qualified service

personnel should install or service this equip- ment. Installation and service performed by

unqualified persons can result in property damage, personal injury or death.

] A CAUTION I These units are not approved for mobile home applications. Such use could result in prop-

erty damage, p_rsonal injury or death.

TABLE OF CONTENTS

INSTALLATION ....................................... 2

OPERATION .......................................... 5

MAINTENANCE ..................................... 6

WIRING DIAGRAMS .............................. 7

WARRANTY ......................................... 10

ManufacturedBy

A.A.C.

A Lennox International Company

421 MonroeStreet

Bellevue,OH 44811

IIIIIIIIIIII)llllllllllllllllllllllllll}lilllllll

I A CAUTION [

The installation of this appliance must conform to the requirements of the National Fire Protection Associa- tion; the National Electrical Code, ANSl/NFPA No. 70 (latest edition) in the United States; the Canadian

Electrical Code Part 1, CSA 22.1 (latest edition) in Canada; and any state or provincial laws or local ordi- nances. Local authorities having jurisdiction should be consulted before installation is made. Such appli-

cable regulations or requirements take precedence over the general instructions in this manual.

Save these instructions for future reference

INSTALLATION

General

=.seinstructions explain the recommended method of

,llation of the PWC heat pump unit and associated

e_uctricalwiring.

the unit inside the carton ifthe carton isdamaged. File a cfaimwith the transportation company. If any damages

are discovered and reported to the carrier DO NOT INSTALL THE UNIT, as claim may be denied.

Check the unit rating p'late to confirm specifications are as ordered.

This unit is designed and approved for use as a self- contained air to air heat pump system.

These instructions, and any instructions packaged with mating components and/or accessories, should be carefully read prior to beginning installation. Note particularly any CAUTIONS or WARNINGS in these instructions and all la- bels on the units.

These instructions are intended as a general guide only, for use by qualified personnel and do not supersede any

national or local codes in any way. Compliance with all local, state, provincial or national codes pertaining to this

type of equipment should be determined priorto installa- tion.

Inspection

Upon receipt of equipment, carefully inspect itfor possible

shipping damage. If damage is found, it should be noted

on the carrier's freight bill. Take special care to examine

Location

The design is certified for through-the-wall installation only. The interior portions of the unit may be surrounded by a

closet with clearances to combustible material held to 0" at sides, 0" top and 0" front ofthe plenum.

The grille side of the unit may be flush with, or extend

beyond, the face of the exterior wall, but should not be recessed more than 2" from the face of the building and

should not be obstructed with trees, landscape materials

or building structure.

There is no minimum clearance required on locating the unit to an interior corner of a building. If the unit is to be enclosed, provisions should be made allowing access to

the indoor side of the unit for changing filters and for

inspection. At least 33" of unobstructed space should be provided infront of the indoor side, whether enclosed or not, to permit removal of the cooling chassis should repairs or inspection be required.

PWCInstallation

Sleeve

F MinimumOpening to

Align with Return Air Opening

In Unit.

VibrationIsolating Matedal

{TopLayer)

Fin-re 1

If the unitis installed in a residential garage, it must be

located or protected to avoid physical damage by vehicles.

The unit must be installed so that no electrical compo-

nents are exposed to water.

[A CAUT,ON]

This unit must be installed level to allow for

proper drainage of the chassis base pan and unit drain pan.

Installing With a Wall Sleeve

[ _, CAUTION l

The sleeve is not intended as the sole support for the unit. An additional support must be

provided near the return opening on the unit

for adequate support. The use of vibration

isolation material between the unit and the support is recommended.

Refer to the installation instructions packed with the wall sleeve and Figure 1 for guidance in assembly and mount-

ing using a wall sleeve.

Make sure the gaskets attached to the sleeve are not damaged.

Seal the space between the wall sleeve and-the building opening with non-hardening caulking compound. The seal

must be weathertight to prevent entrance of moisture and water into the building.

Assure that the unit is completely seated against the gaskets on the wall sleeve.

Installing Without a Wall Sleeve

Refer to the following directions and Figure I for guidance

in installing the unit without a wall sleeve:

Measure the size of the unit and provide an opening in

an outside wall that will accept the unit. Local ordi- nances may require a steel lintel to support the wall

above the opening. The opening must be square in all 4 corners.

Position the unit so that the grilles on the outside face

of the unit are flush or extend beyond the face of the exterior wall, but not recessed more than 2" from the face of the building. Provide a support under the

unit, inside the building. Make sure that the inside

support does not block the return air. The unit should

be installed level

Seal the space between the unit and building opening using a non-hardening caulking compound. The seal mustbe weathertight to prevent entrance of moisture

and water into the building. Make sure the drain holes in the base are not plugged withcaulking,

Condensate Drain

Install the plastic drain tube (furnished) over the 5/8" O.D. fitting welded to the center ofthe condensate pan. Con-

nect the other end of the drain tube to trapped drain line (see Figure 2). The plastic drain connection to the chassis

base is provided so that it may be disconnected from the permanent drain tubing in the base of unitin the event it

becomes necessary to remove the chassis assetnbly.

The drain line should pitch gradually downward at least 1" per 10feet of horizontal run to the open drain.

Be certain that the plastic drain tubing has free drainage and is not crimped or flattened at any bend.

PWC Drain Installation

Drain Pan_

Figure 2

Limitations

The unit should be installed in accordance with all national and local safety codes.

Limitations of the unit and appropriate accessories must also be observed.

The unit must not be installed with any ductwork in the outdoor air stream. The outdoor fan is not designed to

operate against any additional static pressure.

Minimum and maximum operation conditions must be observed to assure maximum system performance with minimum service required. Refer to Table 1 onpage 4 for

the application limitations of the unit.

Application Limitations AirFilter

Outdoor Ambient Air Temperature °F

Minimum DB - Cooling Maximum DB

Cool Heat

125 75

Indoor Ambient Air Temperature °F I

Minimum Maximum

DB/WB DB DB,_VB DB

Cool Heat Cool Heat

62/57 50 90/72 80

Table t

Ductwork

Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Contractors of America (ACCA).

It is recommended that supply and return duct connec-

-'_s at the unit be made with flexible joints.

1ne supply and return air duct systems should be de- signed for the CFM and static requirements of the job.

They should not be sized to match the dimensions of the duct connections on the unit.

Supply duct flanges are shipped flat and must be bent up before attaching the supply duct.

To connect the return duct to the unit, use a straight piece of duct 22" wide by 7" deep. Insert the duct into the return

opening in the bottom of the unit. Flange the duct over the

existing flanges around the opening inside unit. Make sure that all sides of the duct are flanged over to permit removal of cooling chassis if required. Use a flexible

connection to attach remainder of return duct. The return duct should be sealed to the unit casing and terminate

outside the space contai_ningthe furnace.

The return duct must allow for the unit drain pan connections and drain tube.

[ ACAUTION J

no not screw intothe side of the drain pan.

All indoor return air must be filtered. A permanent-type filter is furnished with the unit, located directly behind the

access panel. Removing the panel permits access to the filter.

The filter should be cleaned at least three times during each of the heating and cooling seasons, or more fre- quently if unusual conditions are encountered. To clean the permanent filter, shake filter to remove excess dirt

and/or use a vacuum cleaner. Wash filter in soap or detergent water and replace after filter is dry. It is not necessary to oil the permanent filter after washing.

If an installation is.made in which it is more desirable to mount the filter exterior to the unit, in the return duct work

or elsewhere, the permanent filter can be used or re- placed with a disposable filter. If a disposable filter is used, use the information provided in Table 2 when sizing

the disposable filter.

Minimum Required Surface Area

for Disposable Filters

Model Number Filter Area (minimum)

PWC183 - 480 square inches PWC24,3 480 square inches

Table 2

Thermostat

The room thermostat should be located on an inside wall where it will not be subject to drafts, sun exposure or heat

from electrical fixtures or appliances. Follow the manufacturer's instructions enclosed withthe thermostat

for general installation procedures. Color coded insulated

wires (#18 AWG) should be used to connect the thermo- stat to the unit.

Electrical Connections

All wiring must be done In accordance with the

National Electrical Code (NEC), ANSl/NFPA No. 70 (latest edition); Canadian Electrical Code CSA C22.2 Part I (latest edition); or local codes, where they prevail. Any alteration of internal wiring will void certification and warranty.

Units are factory wired for a 230 volt power supply. If power supply is 208 volts, it will be necessary to change a wire connection on unit transformer from

240 volt terminal to 208 volt terminal as shown on the wiring diagram.

Usewiringwithatemperaturelimitation of 75 =C mini-

mum. Run the 208 or 230 volt, 60 hertz electric power supply through a fused disconnect switch to the control

box of the unit and connect as shown in the wiring dia- gram located onthe inside of the control access panel.

The unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the

National Electrical Code ANSI/NFPA No. 70 (latest edition) or CSA C22.2 Part 1 (latest edition).

Power supply to the unit must be NEC Class 1 and must comply with all applicable codes. A fused disconnect switch should be field provided for the unit. The switch must be separate from all other circuits. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wiring diagram.

Electrical wiring must be sized to minimum circuit ampacity marked on the unit. Use copper conductors

only. Each unitmust be wired with a separate branch circuit and be properly fused.

OPERATION

Sequence of Operation

Cooling

When the thermostat is in the cooling mode, the O circuit

is powered which energizes the reversing valve. Upon cooling demand, the thermostat closes circuit R toY and

G. Closing R to Y closes the unit contactor, starting the compressor and outdoor fan. The thermostat automati- cally closes R to G circuit which also brings on the indoor

blower at the same time. Upon satisfying cooling demand, the thermostat will open the above circuits and open the

main contactor, stopping the compressor and outdoor fan.

If the unit is equipped with a time delay, the blower will

continue to operate for 90 seconds which improves

system efficiency.

Heating

Upon heating demand, the thermostat closes circuit R to

Y, which closes the unit contactor, starting the compressor

and outdoor fan. The reversing valve is not energized in

the heating mode. -The thermostat again automatically

brings on the indoor fan at the same time. The second

stage of the thermostat closes circuit R to W, which closes

the unit sequencers, bringing the auxiliary electric heat on.

Upon satisfying heating demand, the thermostat opens

the above circuits and stops unit operation.

Defrost Cycle

Ifthe outdoor ambient conditions are such that frost forms

on the outdoor coil, the defrost control monitors the need for and initiates and terminates defrost cycles as neces- sary to maintain system performance. The defrost control

is time/temperature initiated and temperature terminated with a maximum defrost time (time-out) of 10 minutes.

Time between defrost cycles is preset at 60ominute

intervals at the factory, but can be field adjusted between

30, 60 or 90 minutes. To field adjust time between defrost cycles, place defrost time plug in the proper position (see

Figure 3). For best performance in Region IV, the PWC243 defrost interval should be adjusted to 30 min-

utes.

Defrost controlwill initiate a defrost cycle ifthe time period

has elapsed and the defrost sensor sees a temperature

below freezing. At the start of a defrost cycle, the defrost

control will energize the reversing valve solenoid, shifting the reversing valve and de-energizing the outdoor fan.

The defrost relay will also close, energizing auxiliary heat for increased comfort during defrost. The unit will remain

in defrost mode until the defrost sensor has determined

that the frost has been removed from the coil or a 10-

minute time period has elapsed.

The defrost control is also equipped with a setof pins to

aid in troubleshooting of the defrost system (see Figure 3).

The following is a brief outline of the testing of the defrost

system.

. Defrost sensor must be closed, 32°F or below. If

temperatures are such that switch will not close,

jumper between defrost sensor terminals on the

defrost control,

2. Start system in heating operation.

Jumper test pins, A 1/4" quick connect terminal crimped onto a solid wire or brazing rod works well for

test jumper. Closing test pins speeds up time interval by a factor of 256.

Defrost

TestPins.,,,=i

Defro=/

TimePlug

Defrost Control

Defrost Control Setting Defrost Test Cycle Time

30 minutes 7 seconds

60 minutes 14 seconds

90 minutes 21 seconds

FinHr

After closing test pins and appropriate cycle time has elapsed, the reversing valve should shift to defrost mode and the outdoor fan should stop. After 2 seconds of

defrost operation, the reversing valve should shift back to

",tingoperation and the outdoor fan should start.

System Performance

For maximum performance of this heat pump system, the operating temperatures and pressures should be checked

and superheat determined at Standard ARI test conditions of 82°F outdoor - 80°F indoor dry bulb/67°F wet bulb. If superheat measured deviates from the values given in Table 3, refrigerant charge should be adjusted accordingly for maximum performance.

Suction Superheat

Outdoor

@ ARI Conditions

Unit

82 ° OD

Model

80° IDDB/67 ° IDWB

PWC183 18° - 20° F PWC243 17° - 19° F

Motors

The indoor and outdoor fan motors are permanently

lubricated and require no maintenance.

Outdoor Coil

Foreign material should not be allowed to accumulate on the outdoor coil surface or other parts in the air circuit.

Cleaning should be as often as necessary to keep the coil clean. Use a brush, vacuum cleaner attachment or other suitable means. Be sure power to unit is shut off

before using water to clean the coil.

Care should be used when cleaning the coils so that the coil fins are not damaged.

Outdoor Base Drain

Foreign material should not be allowed to clogthe drain hole. inspect and clear drain opening priorto heating season.

Table 3

MAINTENANCE

Shutoff all electrical power to the unit before conducting any maintenance procedures. Failure to do so could cause personal injury.

Periodic inspection and maintenance normally consists of changing or cleaning filters and (under some conditions) cleaning the coils.

Filter

Inspect the filter once a month. Replace disposable filter

or clean the permanent-type filter as necessary (a mini-

mum ofthree times each heating or cooling season is recommended). Do not replace permanent-type filter with a disposable filter unless an installation was made in which the filter was mounted exterior to the unit (see Air

Filter section on page 4).

208/230-1-60

POWERSUPPLYWITHMIN.

75"CCOPPERWIRE

I CIRCUIT1I I (lo_cO_L'qCIRCUIT2I

•; ..; : :

P_D

BLACK

LOWER MOTORvloI_rr

RED

UNE VOLTAGE-FACTORY UNE VOLTAGE-RELD

........ UNE VOLTAGE-RELD (IF USED)

LOW VOLTAGE-FACTORY

.......... LOW VOLTAGE-FIELD

7 AND 10 PWC ONLY

BLOWER

(

CAPACr_R-RUN

BLUE

NOTE:

IF ANY OF THE ORIGINAL WIRES ARE REP_, THE

SAME SIZE AND TYPE WIRE MUST BE USED.

CONNECTOR

CONDENSER FAN

BLACK

BROWN

REV

VALVE

DEFROST

SENSOR

Connection Diagram

PWC with 5, 7 or 10 KW Heat Strip

Part #41164-3

Fin.r== 4

208/230-1-60

:OWER SUPPLY WITH MIN.

75"C COPPER WIRE

I CIRCUIT 1 I CIRCUIT 2

: i : :

: •

RED F_

UNE VOLTAGE-FACTORY

..... LINE VOLTAGE-RELD

........ LINE VOLTAGE-FIELD (IF USED)

LOW VOLTAGE-FACTORY

.......... LOW VOLTAGE-R ELD

BLUE

UMrT

BLOWER

CAPACITOR-RUN

RED

DEFROST

NOTE:

IF ANY OF THE ORIGINAL

WIRES ARE REPLACED, THE SAME SIZE AND TYPE WIRE

MUST BE USED.

CONNECTOR

BLOCK

CONDENSER FAN

E_CK

REV

VALVE

Connection Diagram

PWC with 15 KW Heat Strip

Part #42203-2

208/230-1-60

POWER SUPPLY WITH MIN.

75"C COPPER WIRE

LINE VOLTAGE-FACTORY

..... UNE VOLTAGE-FIELD

........ UNE VOLTAGE-FIELD (IF USED)

LOWVOLTAGE-FACTORY THERMOSTAT

.......... LOW VOLTAGE-FIELD

NOTE:

IF ANY OF THE ORIGINAL WIRES ARE REPLACED, THE

SAME SIZE AND TYPE WIRE MUST BE USED.

BLOWER MOTOR

BLOWER

I_)

RED

_-RUN

RE)

CONDENSER FAN

BROWN

: : °

, POTENTIAL

RELAY

pFUSe_

Connection Diagram

PWC with No Heat Strip

Part #45322-1

Fin-r== 6

Limited Warranty

August 1, 1997

Thiswarran(ygivesyou specificlegalrightsand you may have otherrights

which vary from state/provincetostate/province.

Warrantor: Armstrong Air Conditioning Inc., 421 Monroe St., Bellevue, OH 44811

Armstrong Air Conditioning Inc products are available under the following names: Air Ease, Armstrong Air, American Airs, Concord

Subject to the limitafions.stated in this warranty, we warrant to the first buyer for use the residential heating, cooling or heat pump unit, when installed, operated and maintained as required by this warranty, to be free of defects in workmanship or material for a pehod of five years (two years

for commercial equipment) from the time of installation. We will replace any defective component without cost or expense to you except for the costs of delivery and labor for removal and replacement of the defective component.

Warranty Begins

The warranty period begins when the installafion iscomplete and the product is ready to operate. You must be able to verity this date whenever a warranty claim is made. Original bill of sale, installer's invoice or other similar document will suffice..If the beginnir_gdate cannot be Verified. we will

consider warranty coverage to begin six months after the date the product was shipped from our factory.

Limitations on Implied Warranties

Implied warranties of merchantability or, to the extent applicable, fitness for a particular purpose are timited to five years, the same duration as the basic limited written warranty provided herein. Some states/provincas do not allow limitations on how tong an implied warranty of merchantability or

fitness lasts, so the above limitations dr exclusions may not apply to you.

Only Warranty

This written Limited Warranty is the only warranty made by the warrantor; this warranty is in lieu of and excludes all other warranties, express or

implied. The warrantor does not authorize any person to provide any other warranty or to assume for it any further obligation in connection withthe

warranted product.

What is NOT Covered

I. Cabinets or cabinet pieces.

2. Normal maintenance items such as filters, fan belts, fuses or other consumable items. 3 Damage caused by misuse, failure to maintain properly, accidents or acts of God. 4 External wiring, piping, venting or attachment of accessory products not integral to our product, including without limitation, humidifier,

air cleaner, vent damper, thermostat or other mechanical devices not manufactured by the warrantor.

5 Products that have been operated in a corrosive atmosphere where e concentration of acids, halogenated hydrocarbons or other

corrosive elements causes deterioratfon to metsi surfaces or integral components. NOTE: Operation in a corrosive atmosphere is considered abuse and voids this warranty

6 Products that have NOT been installed in accordance with our published installation instructions, applicable focal, state/provincial or

national codes, ACCA published standards.

7 Products that have NOT been installed by competent, qualified installers. 8 Products that have been moved from their odginai place of installation.

Warranty on Replacement Components

Any replscement component furnished by us will assume the remaining (unused) portion of the Limited Warranty.

Consequential Damages

The warrantor shall not be responsible for any consequential damages caused by any defect in the product. Some state/provinces do not allow the

exclusion or limitations of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

NOTE: After the first year, in the event that a gas or oil heat exchanger is no longer being manufactured by the warrantor, the warrantor will allow a

credit equal to the then current wholesale price of an equivalent heat exchanger towards the purchase of a new Armstrong gas or oil furnace.

This product must be installed, used and cared for in accordance with the instructiott manual You are responsible for required pedodic maintenance or service, such as changing or cleaning of air filters and lubrication or cleaning of components. Failure to properly install, operate or maintain your

unit voids this warranty.

Model #

, INSTALLED BY:

I ealer

Address

Telephone #

Owner Record

Serial # Installation Date

License #

INSTALLATION INSTRUCTIONS

Wall Sleeve Kit CA239

For Use With

HW/HWC/EWC/PWC Series

Magic-Pak Thru-the-Wall Unit

age_

_WARNING

Parts List

Quantity Description

1 TopPanel 1 BottomPanel

1 Right Side Panel 1 LeftSide Panel

2 Squaring Braces

1 Top SupportAngle

2 SideSupportAngles

24 #8 x 3/8" Screws

1 InstallationInstructions

Manufactured By

A.A.C.

A Lennox International Company

421 Monroe Street

Bellevue,OH 44811

General

The wall sleeve isdesignedto facilitatethe installationof Magic-Pakunits by providingan accurateopeningduring buildingconstruction.The use ofa wall sleeve allows units toremain off-siteuntilbuildingconstructionapproaches completion.

The wall sleeve iscomprisedof fourassemblies (top,bottom,and rightand left sides) which easily slip togetheron the job toform a rectangularbox correctly

sizedto receive a Magic-Pak unit.

When inplace and securely fastened, the wall sleeve openingprovideseasy access to the finishedwall pedm- efarfor caulksealing.

The weather-seal caulkingiseasier to performwhen the sleeveprotrudesbeyondthe finishedwall by 3/8" to 1".

Inspection of Shipment

Ifany damage tothe contentsofthis kit isfound at the timeof delivery,propernotificationshould be made onthe carrier's freight bill.Damage claimsshould be filedwith

thecarrierat once. Claimsof shortage should be filedwith

the manufacturerwithin 5 days.

1111111Ill1111111111IllIllIIIIIIIIIRillIIIIIIII

Save these instructionsforfuture reference

INSTALLATION

Wall Sleeve Assembly

Toassemble the wall sleeve, refer to the followinginstruc- tionsand Figure 1.

1. Slidetop panel over side panels untilretaining clips

are engaged in slottedopenings.

Place side and top assemblydown withthe front

flange againstfloorand slidebottom panel intoside

panelslip strips untiltabs on bottom panels are locked inplace.

3. Attach squaring bracesto top and side panels using

existingholes. (Do not remove braces untilwall sleeve issecured to building.)

Attachthe supportanglesto top and side panels usingthe #8 x 318"screwsprovided.Two sets of holes are providedin the panels for attaching the support angles. Use the rowof holes nearest the front of the sleeveto attach the support anglesfor 1"spacing or the secondset of holesfor 3-3/4" spacing.

The wall sleeve must be square in opening before securing sleeve to building. This is requiredto assure the Magic-Pak unitwill slide intothe sleeve.

Caulk all seams where the bottompaneljoins tothe side panels includingthefront corners ofthe bottom panel and the top of side panel slipjoints.Caulk sealing is bestaccomplishedafterthe wall sleeve is assembledbutbefore Risplaced inthe wall opening. Remainingfinalcaulk sealing can be done just after the sleeve issecured intothe wall opening, if desired, to avoidbreakingthe seal duringhandling.

Wall Sleeve Assembly

TopPanel

P/N33021B000

Frontof

RightSide Panel P/N 33024B002-

Squaring

Braces

P/N33048B000

LeftSide Panel P/N 33024B001

Side SupportAnglePIN 33027BG00- 2 Side=

Figure I

Furthersealing againstair infiltrationmustbe done alter the Magic-Pak unitis installedin the wall sleeve and utility connectionshavebeen completed (see Sealing/Weath-

erproofing Wall Sleeves section).

Wall Sleeve Installation

The wall sleeve may be installedfrom either the insideor outsideofthe building.

Some builderswillattach the wall sleeve to the support wallthroughthe side supportangleswhether they are insertingthesleeve fromthe outsideor the inside.Othem willuse the side angles simplyas a locating"stop"to achievethe appropriatedimensionwhileshootingfasten- ersthroughthe sides ofthe wallsleeve into the supporting wall.In either case,the wall sleeve must be fastened to the supporting wall and notto thefinishedwall.

The sleeve may extend farther than 1"beyondthe finished wall,but reachingtheperimeter ofthe openingfrom inside for sealing becomes increasinglydifficult.In any case, adequate safety precautionsmust beconsideredto protectpersonnel.

Instailing Wall Sleeve from Inside

The most popular method ofinstallingthe wallsleeve is from the inside of the buildingwiththe weather seal appliedfrom the outsideas the finishwall is applied.

Instalflng Wall Sleeve from Outside

In manyhigh-rise constructionapplications,contractors insertthe wall sleevesfrom the outsidewhilethewall is

beingconstructed.The two-sidedsupport anglesshould then be attached to the wall sleeve sides at a locationthat

willexceed the thicknessofthe outsidefinish wallbythe

recommended3/8" to 1"dimension.

Forexample, ifthe supportingwall is concreteblockwith a brickfacing, there is usuallya space betweenthe block and the brick.This space dimensionmust be addedto the widthof the brick (plus3/8" to 1") so thatwhen the sleeve is inserted intothe blockwall opening, up to the angles and fastened to the blockwallbefore thebrickis installed, the sleevewilt protrudebeyondthe finishedbrickby 3/8" to 1",as needed for caulk sealing.

The same applies if the supportingwall iswoodframe.

One may insertthe sleevefromthe outside upto the angleslocated on each side,allowingforthe thicknessof sheathing,finishsiding,and caulk sealing.

Recessed Sleeves

In someapplications,where either the buildingwallsare verythick(over 16") or architecturaldesign dictates,units

can berecessed. Avoidrecessingthewall sleeve ifthe wallopening is requiredto be the same size as the wall

sleeveopening. However,if the wall openingcan be larger

inverticaldimensionthan the wall sleeve sothat the bottomcan rest ona sillthat isat least2"higher thanthe bottomof thewall opening,some recessing ispermitted.

Thissillshouldbe recessed further than the sleeve by3/8"

to 1"to permitweather-seal caulking along the bottom

edge withoutpluggingthe drain holes in the sleeve.

The topof the wall opening should be above the topof the

wall sleevebya dimensionequal to or greater than the

amountof the recess in orderto avoid restrictionof the condenserdischargeair.

Sealing/Weatherproofing Wall Sleeves

A highgrade non-hardeningcaulkingcompoundapproved forexterioruse mustbe appliedoutsidearoundthe perimeterofthe wall sleeveand the finishedwall. Caulk shouldalso beapplied around the sleeve's perimeter and

thefinishedinteriorwall.

Final sealingagainst air infiltrationmust be donealter the Magic-Pakunit is installedin thewall sleeve. For additional protection,the space between the unit and the wall sleeve

shouldbe sealed on all sideswith a bead of sealant.

2--I=

Wall Sleeve Dimensions (in.)

-$--

_t._

I.---- z9- -,4

Flar_es may b_ assembl_l

1"or 5_/4"from this e_e ofthe elc_v_

<.. 1or 3_/4

.16,.._15 or 12_

Figure 2

I_A_T_°.I 4"948°96----I

INSTALLATION

ANDMAINTENANCE

INSTRUCTIONS

PWCSERIES

SELF-CONTAINEDHEATPUMP

ManufacturedBy

ARMSTRONG AIR CONDITIONING INC.

A LENNOXInternationalInc. Company

421 MonroeStreel

I PART.OI .,,,,RO..I OATE12''0 I SUPERSEOESI I PAGE2OF,0

GENERAL

Theseinstructionsexplainthe recommendedmethodof installationof the PWCheatpumpunit and associatedelec- tricalwiring.

This unit is designed and approvedfor use as a self-containedairto air heat pump system.

These instructions,and anyinstructions packagedwith maling componentsand/or accessories,shouldbe carefully read priorto beginning installation.Note parliculady anyCAUTIONSor NOTESin theseinstructions andall labels on

the unit.

Theseinstructionsare intendedasa generalguideonly.for use byqualifiedpersonnel,anddo notsupersedeanyna- tionalor localcodesinanyway. Compliancewithalllocal,state, provincial,or nationalcodespertainingtothistypeof equipmentshouldhe determinedprior to installation.

INSPECTIONOFSHIPMENT

Uponreceiptof equipment,carefullyinspectit forpossibleshippingdamage.Ifdamageis found,it shouldbe noted

on the carder's freightbill. Take specialcareto examinethe unit insidethecartonif the cartonis damaged.File a

claimwith the transportationcompany.

If any damagesare discoveredand reportedto the carrier DONOTINSTALLTHE UNIT as claim may be denied.

Checkthe unitrating plate to confirmspecificationsare as ordered.

CAUTION:INSTALLATIONANDSERVICINGOFAIR CONDITIONINGEQUIPMENTCANREHAZARDOUSDUETO IN- TERNALREFRIGERANTPRESSUREAND LIVE ELECTRICALCOMPONENTS.ONLYTRAINEDANOQUALIFIEDSER- VICE PERSONNELSHOULDINSTALL,REPAIR,OR SERVICETHIS EQUIPMENT.

WARNING

FORYOURSAFETY DONOTSTOREOR USEGASOLINEOROTHERFLAMMABLEVAPORSAND LIQUIDSINTHE VICINITYOFTHIS ORANY OTHERAPPLIANCE.

NOMENCLATURE:

1. ELECTRICHEATING

5 = 5kW

7 = .7kW 10 = 10kW 15 = 15kW

2. PWC=(HEAT) PUMPWITH COOLING

3. COOLINGCAPACITYTONNAGE 182 = 1½ TON

242 = 2 TON 302 = 2½ TON

10 PWC 242 A-1A

1 2 3 4 5

4. ElectricalRatingCode: A=208/230 volts; OOHz; 1 phase,

5. RevisionCode

PARTNO. I 41194BOg6I DATE I 2-1-96 I SUPERSEDESI 411940094 I PAGE3OFIO

LOCATION

Thedesigniscertifiedfor through-the-wallinstallationonly. Theinteriorportionsoftheunit may be surroundedbya closetwith clearancestocombustiblematerial heldto 0" at sides, 0" top and O" frontof the plenum.

Thegrillesideofthe unitmay beflushwith orextendbeyondthefaceof theexteriorwall, butshouldnotberecessed

morethan two(2) inchesfrom the face of thebuildingand shouldnotbe obstructedwithtrees, landscapematerials, or buildingstructure.

Thereis nominimumclearancerequiredonlocatinga unittoaninteriorcornerofa building. If theunitis tobeenclos- ed, provisionsshouldbemadeallowingaccesstothe indoorsideof theunitfor changingfilters.and forinspection.At least33" of unobstructedspaceshouldbe providedin front of the indoorside. whetherenclosedornoL to permit removalof the coolingchassisshouldrepairsor inspectionbe required.

If this unitis installedina residentialgarageit must be locatedor protectedtoavoidph_,sicaldamagebyvehicles. Thisunit must be installedso that no electricalcomponentsare exposedto water.

INSTALLATION

CAUTION:THESLEEVEISNOTINTENDEDASTHESOLESUPPORTFORTHEUNIT. ANADDITIONALSUPPORTMUST BE PROVIDEDNEARTHE RETURNOPENINGON THE UNIT FOR ADEQUATESUPPORT.THE USEOF VIBRATION ISOLATIONMATERIALBETWEENTHE UNIT ANDTHE SUPPORTIS RECOMMENDED,

CAUTION:THIS UNITMUST BEINSTALLEDLEVELFORPROPERDRAINAGEOFTHE CHASSISBASEPANAND UNIT DRAINPAN.

WITHOUTWALLSLEEVE

Measurethesizeoftheunit andprovideanopeninginan outsidewall that willaccepttheunit. Localordinancesmay require a steel lintel to supportthe wall abovethe opening.Thisopeningmust be square in all corners.

Positiontheunitsothat thegrilleson the outsidefaceof the unit areflushor extendbeyondthe faceof the exterior wall,but notrecessedmorethantwo(2) inchesfromthe faceof thebuilding.PROVIOEA SUPPORTUNDERTHE UNIT

INSIDETHE BUILDING.Makesure thattheinsidesupportdoesnot blockthereturnair. The unitshouldbeinstalled

level.

Sealthe spacebetweentheunit and the buildingopeningusinga non-hardeningcaulkingcompound.Thesealmust beweather-tighttoprevententranceof moistureandwater intothe building.Makesure thedrainholesin the base are notpluggedwith caulking.

WITH WALL SLEEVE

Seethe installationinstructionspacked with Ihe wall sleeveto assembleand mountin a wall. Make sure that the

gasketsattachedtothe sleeveare notdamaged.Assurethatthe unit iscompletelyseatedagainstthe gasketsonthe wall sleeve.

Sealspacebetweenwall sleeveand buildingopeningusingnon-hardeningcaulkingcompound.This seal mustbe watertight.

CONDENSATEDRAIN

Install theplasticdraintube(furnished)overthe5/8" O.O. fittingwelded to thecondensatepan. Connectotherend

ofthe draintubeto trappeddrain line(See Figure2). Theplasticdrain connectiontothechassisbaseisprovidedso thatit may bedisconnectedfromthepermanentdrain tubingin thebaseof unitin theeventit becomesnecessaryto removethe chassisassembly.

The drain line should pitch gradualtydownwardat least 1" per 10 footof horizontalrun to the opendrain.

Be certainthat the plasticdrain tubing hastreedrainageand is notcrimpedor flattenedat anybend.

PA.T.O.I ,,,,_,,.0_,I 0','_ I _'"_ I SU"ERSEOESI ""_"00_"I PA_E,'O_,O

FIGURE1

INSTRUCTIONFORSUPPORTINGPWCUNITS

Wall Sleeve

7 x 22 Min. OpeningTo

A#ignwith'Return Air

Openingin Unit.

VibrationIsolatingMaterial

Plywood

FIGURE2

DRAINPAN

5/8 " I.D. PLASTIC

(FURNISHED)

CHASSISDRAIN

'ASSEMBLY

(FURNISHED)

5/8" I,O. PLASTIC TU"BE(FURNISHEO]

RETURN

AIR DUCT\

5/8" O.O. DRAIN

_LINEAND TRAP

(iNSTALLERSUPPLIED)

.ARTNO.I "f9"Bog I OATEI 2"t'g6I .SUPERSEOESI 4119'0094[ PAGESOFtO

LIMITATIONS

The unit shouldbe installedin accordancewithall nationaland local safetycodes.

Limitationsof the unitand appropriateaccessoriesmust also be observed.

The unitmustNOTbe installedwithany ductwork in theoutdoorairstream,Theoutdoor fanisnotdesignedtooperate againstany additionalstaticpressure.

Minimum and maximum operating conditionsmust be observedto assure maximumsystem performancewith minimum servicerequired,

TABLE1 - APPLICATIONLIMITATIONS

OUTDOORAMBIENTAIR TEMP. OF INDOORAMBIENTTEMP. °F

MIN, DB - COOL MAX, DB MIN. MAX.

65 COOL HEAT OB/WB DB DB/WB DO

125 75

COOL HEAT COOL HEAT

62/57 50 90/72 80

DUCTWORK

Ductwork shouldbe designedand sizedaccordingto applicablemethods fromthe Air ConditioningContractorsof

America(ACCA).

It is recommendedthat supplyand return duct connectionsat the unit be madewith flexible joints.

' The supplyand return air ductsystemsshouldbe designedfortheCFM staiicrequirementsofthejob. Theyshould

NOT be sized Io matchthe dimensionsol theduct connectionsonthe unit.

NOTE:SUPPLYDUCTFLANGESARESHIPPEDFLATAND MUSTBEBENTUP BEFOREAFI'ACHINGTHESUPPLYDUCT,

ToconnectthereturnducttotheunJt,usea straightpieceofduct22" wideby 7" deep.Inserttheductintothereturn openingin thebottomoftheunit. Flangetheductovertheexistingflangesaroundtheopeninginsideunit.Makesure

thatall sidesoftheductare flangedovertopermitremovalofcoolingchassisifrequired.Usea flexibleconnectionto

attachremainderofreturnduct.The returnductshouldbesealedto theunitcasingand terminateoutsidethe space

containingthe furnace,

NOTE:THE RETURNDUCTMUST ALLOWFORTHE UNIT DRAINPANCONNECTIONSAND DRAINTUBE.

CAUTION:00 NOT SCREWINTOTHE SIDEOF THE DRAIN PAN.

AIR FILTER

Allindoorreturn airmustbefiltered.A permanent-type filter isfurnished withtheunit. locateddirectly behindtheac- cess panel. Removingthe panelpermitsaccessto the filter.

The tiltershouldbecleanedatleastthreetimesduringeachof the heatingandcoolingseasons,ormorefrequently if unusualconditionsare encountered.To cleanthe permanentfiller, shakefilter to removeexcessdirt and/or use

vacuumcleaner. Washtilter in soapor detergentwaterand replacealter filteris dry.

The filter suppliedneed not be oiledalter washing.

I PA.TNoI .tt9..o96I DATE12196 I SUPERSEDESI ,rig.DO9.I PAGE,O.tO

It an installation is madein which it is moredesirableto mountthe filter exterior tothe unit, in the return duct work, or olherwise, either the permanent filter supplied or a disposablefilter may be used. If a disposable filter is used, the

minimum area required is as follows:

MOOELNO. FILTERAREA(MtN.)

PWC 182 480 sq. in.

PWC242 480 sq. in. PWC302 480 sq. in.

THERMOSTAT

The room thermostatshouldbe locatedonan insidewall whereitwilt not be subjectto drafts, sun exposureor heat

from electricalfixturesorappliances.Followthemanufacturer'sinstructionsenclosedwiththethermostatforgeneral installationprocedures.Colorcodedinsulatedwires(#18 AWG)shouldbe usedtoconnectthethermostattothe unit.

POWERAND CONTROLWIRING ELECTRICALCONNECTIONS

ALLWIRINGSHOULDBEDONEIN ACCORDANCEWITHNATIONALELECTRICALCODE,ANSI/NFPA NO.70 (LATEST

EDITION).IN CANADA(_SAC22.2 Part 1 (LATESTEDITION),ORWITH LOCAL CODES,WHERETHEY PREVAIL. NOTE:UNITSAREFACTORYWIREDFORA 230 VOLTPOWERSUPPLY. IF POWERSUPPLYIS 208 VOLTS.IT WILL

BENECESSARYTOCHANGEAWIRE CONNECTIONONUNIT TRANSFORMERFROM240VTERMINALTO20SV TER- MINALAS SHOWNONWIRING DIAGRAM.

Usewiringwitha temperaturelimitationof 75°C rain. Runthe208 or 230 volt,60 hertzelectricpowersupplythrough

a fuseddisconnectswitchtothe controlboxof the unitandconnectas showninthe wiringdiagramlocatedon the in-

sideof the controlaccesspanel. The unitmustbe electricallygroundedin accordancewith local codesor in the absenceof localcodeswith the Na-

tionalElectricCodeANSI/NFPA No. 70 (latestedition)or CSAC22.2 Part 1 (latestedition).

suppliedwith the unit must be replaced, replacementwiremustbe of the type shownon the wiring diagram.

Electricalwiringmust besized tominimumcircuitampacitymarkedonthe unit. USECOPPERCONDUCTORSONLYI Eachunit must bewired with a separatebranchcircuitand be properlyfused.

SEQUENCEOFUNIT OPERATION

COOLING- WhenthethermostatisIn the coo[ingmode,the Ocircuitis poweredwhichenergizesthereversing valve.

Uponcoolingdemand,thethermostatclosescircuitRtoYand G.ClosingR toY closestheunitcontactor,startingthe compressorandoutdoorfan. ThethermostatautomaticallyclosesRto Gcircuitwhichalsobringsonthe indoorblower at thesametime. Uponsatisfyingcoolingdemand,thethermostatwillopentheabovecircuitsandopenthemaincon- tactor,stoppingthe compressorand outdoorfan.If the unitis equippedwith a time delay,the blowerwillcontinueto operate.for 90 secondswhich improvessystemefficiency.

HEATING- Uponheatingdemandthe thermostatclosescircuit R to Y closingthe unitcontactor,startingthe com-

pressorandoutdoorfan.The reversing valveis notenergizedin the heating mode.Thethermostatagainautomatical-

ly bringsonthe indoorblower at the sametime. Thesecondstageofthethermostatclosescircuit RtoW closingthe

unitsequencers,bringthe auxiliaryelectricheaton.Uponsatisfyingheatingdemandthethermostatopensabovecir- cuits and stopsunit operation.

DEFROSTCYCLE- If outdoor ambientconditionsare such that frost formson theoutdoorcoil, the defrost control

monitorsthe need for andinitiates and terminatesdefrost cyclesasneccessary to maintain system performance.The

defrost controlis time/temperatureinitiated and temperature terminated with a maximum defrost time (time-out)of

10 minutes. Timebetweendefrost cyclesis pre-set at 60 minuteintervalsat thefactory, but canbefield adjustedto

30, 60, or 90 minutes.Seeillustrationfor field adjustmentofdefrosttiming.For bestperformancein RegionIV, the

PWC242defrostinterval shouldbeadjustedto30 minutes.

PA...o,I .,,9.o09.I

IDNSTALLATION

AN MAINTENANCE

INSTRUCTIONS

PWCSERIES

SELF-CONTAINEDHEATPUMP

PARTNO.] 4,,94°O94I OA_E] 4-,5-94I SU_RSEOESI .EWI _'AGE_O_IOI

Manulaclured By

ARMSTRONG AIR CONDITIONING INC,

A LENNOXInternationalInc. Company

421 Monroe Slreel

Bellevue, OH44811

PART NO.

I 4,tg4ooB4I DATEI 4lsg, I SUPERSEOESI NEWI PAGE2OFlO

GENERAL

Theseinstructionsexplainthe recommendedmethodof installationof the PWCheal pumpunitandassociatedelec-

trical wiring.

This unil is designed and approvedfor use as a self-contained air Io air heat pump system.

Theseinstructions, andany instructions packaged wilh mating componen[sandlor accessories,should becarefully read prior to beginning inslallation, Noleparlicularly any CAUTIONSor NOTESin these instructions and all labelson

the unit.

Theseinslructions are intended asa generalguideonly, foruse byqualifiedpersonnel, andtienotsupersedeanyna-

tionalorlocalcodesinanyway. Compliancewithall local, state,provincial,ornationalcodespertainingtothistypeof equipmentshouldbe determinedpriorto instaltalion.

INSPECTIONOFSHIPMENT

Uponreceiptof equipment,carefullyinspectil for possibleshippingdamage. If damageis found, itshouldbenoied

on the carrier'sfreight bill. Take specialcare to examinethe unitinsidethe cartonif thecartonisdamaged. Filea claimwilh thetransportationcompany,

If anydamages arediscovered and reportedtothe carrierDONOTINSTALLTIlE UNIT as claimmay be denied.

Checkthe unitrating plateto confirmspecifications are asordered. CAUTION:INSTALLATIONAND SERVICINGOFAIR CONDITIONINGEQUIPMENTCAN BEHAZARDOUSDUETOIN-

TERNALREFRIGERANTPRESSUREAND LIVE ELECTRICALCOMPONENTS.ONLYTRAINEDANDQUALIFIEDSER- VICE PERSONNELSHOULDINSTALL,REPAIR,ORSERVICETHIS EQUIPMENT.

I WARNING

FORYOURSAFETY

DONOTSTOREORUSEGASOLINEOROTHERFLAMMABLEVAPORSANDLIQUIDSIN THEVICINITYOFTHIS

ORANY OTHERAPPLIANCE.

NOMENCLATURE:

10 PWC 242 A-1A

1 2 3 4 5

1. ELECTRICHEATING 4. ElectricalRatingCode: 5 = 5kW A=208/230 volts;60 Hz; 1 phase 7 = 7kW

10 = lOkW 5. RevisionCode

15 = 15kW

2. PWC=(HEAT) PUMPWITH COOLING

3. COOLING CAPACITYTONNAGE 182 = 1'IzTON 242 = 2 TON 302 = 2'/2TON

I PA,,NO.I ,, g,o094I DATEI '-fS-g'I SUPERSEDESI ,EW I PAGE3OF,O

LOCATION Thedesign iscertifiedfor through-the-wallinstallationonly.The interiorportionsof theunit may besurroundedby a

cJosetwith clearancesto combustiblematerial held to O" at sides, 0" topand 0" frontof the plenum. Thegrille sideof the unit maybe flush with or extendbeyondthefaceof theexteriorwall,but shouldnotberecessed

more than two (2) inchesfrom the face of thebuilding andshould notbeobstructed with trees, landscapematerials, or building structure.

least 33" ol unobstructed space should be provided in fronl of the indoorside, whether enclosed or not, to permit removalof the coolingchassis shouJdrepairs or inspection be required,

If this unit is installed in a residential garage it must belocated or protectedto avoidphysical damageby vehicles. This unit must be installed so that no electrical componentsare exposedtowater.

INSTALLATION CAUTION:THESLEEVEIS NOTINTENDEDASTHESOLESUPPORTFORTHEUNIT.ANADDITIONALSUPPORTMUST

BEPROVIDEDNEARTHE RETURNOPENINGONTHE UNIT FORADEQUATESUPPORT.THE USE OF VIBRATION ISOLATIONMATERIALBETWEENTHE UNIT AND THESUPPORTIS RECOMMENDED.

CAUTION:THISUNITMUSTBE INSTALLEOLEVELFORPROPERDRAINAGEOFTHECHASSISBASEPANAND UNIT DRAINPAN.

WITHOUTWALLSLEEVE

Measurethesizeofthe unit andprovideanopeningin an outsidewallthatwillaccepttheunit. Localordinancesmay require a steel lintelto supportthe wall abovethe opening.This openingmust be square in all corners.

Positionthe unitsothatthe gritles on the outsideface of theunitare flush or extendbeyondthe faceof theexterior

wall, but notrecessedmorethan two (2) inchesfromthe face of thebuilding. PROVIDEASUPPORTUNDERTHEUNIT INSIDETHE BUILDING.Makesure that theinsidesupport does not block the return air. The unitshouldbe installed

level.

Sealthespacebetweenthe unitandthe buildingopening usinga non-hardeningcaulkingcompound.Thesealmust be weather-tight toprevententrance ol moisture andwaterinto thebuilding. Make surethe drainholesin the base

are not plugged with caulking.

WITH WALL SLEEVE

Seethe installationinstructionspacked with the wall sleeveto assembleandamountin a wall. Make surethat the gaskets attachedtothe sleeveare not damaged. Assurethat the unitiscompletelyseatedagainst the gaskets onthe

wall sleeve.

Sealspacebetweenwail sleeveand building opening using non-hardeningcaulkingcompound.This sealmust be

watertight,

CONDENSATEDRAIN

Install theplastic drain tube(furnished) over the 5/8" O.D. fitting weldedtothe condensatepan. Connectotherend of the drain tubetotrapped drain line (See Figure2). Theplastic drain connectionto thechassisbaseis providedso that it may be disconnected from the permanent drain tubingin thebaseof unitin theevent it becomesnecessaryto remove the chassis assembly.

The drain lineshouldpitch gradually downward at least 1" per 10 loot of horizontal run to the open drain. Be certainthat the plaslic drain tubing has freedrainage and is not crimpedor flattened at any bend,

I PART.O.I "(940094[ DArEI 4-_5-9'I SUPERSEDES

NEW [

PAGE4 OF 10

FIGURE1

INSTRUCTIONFORSUPPORTINGPWCUNITS

WallSleeve

7 x 22 Mio. OpeningTo

Align with ReturnAir

Opening _n Unit.

]

VibrationisolatingMaterial

FIGURE2

5/8 "I.D. PLASTIC

(FURNISHED)

CHASSISDRAIN

(FURNISHED)

5/8" I.D. PLASTIC TUBE(FURNISHED)

RETURN

NR DUCT

\ \

518" O.O. DRAIN

"-UNE AND TRAP

(INSTALLERSUPPLIED)

PA,TNOI 4tt94OOB4I DA EI 41594]SUPERSEDESI NEWI PAGE OFtO

LIMITATIONS

The unitshouldbe installedin accordancewith all national and localsafetycodes.

Limitationsofthe unit and appropriateaccessoriesmust alsobe observed.

TheunitmustNOTbeinstalledwithany ductworkin theoutdoorairstream.Theoutdoorfan is notdesignedto operate againstany additionalstatic pressure.

Minimumand maximum,operatingconditionsmust be observed to assure maximumsystem performancewith minimum servicerequired.

TABLE1 - APPLICATIONLIMITATIONS

OUTDOORAMBIENTAIR TEMP. OF

MIN. OB" COOL MAX. OB

65 COOL HEAT

125 75

DUCTWORK

INDOORAMBIENTTEMP. OF

MIN. MAX.

DB/WB DB DB/WB DB

COOL HEAT COOL HEAT

62/57 50 90/72 80

Ductworkshouldbe designed_lndsized accordingto applicablemethodsfrom theAir Conditioning Contractorsof

America(ACCA).

It is recommendedthatsupplyand return duct connectionsat theunit be madewith flexible joints.

The supptyandreturn air ductsystemsshouldbedesignedfor the CFMstaticrequirementsof the job. Theyshould NOTbe sizedtomatch thedimensionsof the ductconnectionsonthe unit,

NOTE:SUPPLYDUCTFLANGESARESHIPPEDFLATANDMUSTBEBENTUPBEFOREATTACHINGTHESUPPLYDUCT.

Toconnectthe returnducttotheunit.usea straightpieceof duct 22" wideby 7" deep.Inserttheductintothereturn openinginthebottomoftheunit. Flangetheductovertheexistingflanges aroundtheopeninginsideunit. Make sure thatallsidesofthe ductare flangedovertopermitremovalofcoolingchassisif required.Usea flexible connectionto attachremainderofreturnduct.Thereturnductshouldbesealedtothe unit casingandterminateoutsidethespace containingthefurnace.

NOTE:THE RETURNDUCTMUST ALLOWFORTHE UNIT DRAINPANCONNECTIONSANDDRAINTUBE.

CAUTION:DONOTSCREWINTOTHE SIDEOFTHEDRAINPAN.

AIR FILTER

Allindoor return airmust befiltered.A permanent-typefilter isfurnished withtheunit,locateddirectly behindtheac- cess panel. Removingthe panel permits access to the filter.

Thefiltershouldbe cleanedat leastthreetimesduring eachof theheatingandcoolingseasons,or morefrequently if

unusual conditionsare encountered. To clean the permanent filter, shake filter to removeexcessdirt and/or use

vacuum cleaner. Wash filter in soap or detergent water and replaceafter filter is dry.

The filtersupplied neednot be oiled afterwashing.

PARTNO. ] 41194D094 ] DATE ] 4-15-94 ] SUPERSEDES ] NEW ] PAGE6 OF 10

If aninstallation is madein which it is more desirabletomount thefilter exterior tothe unit, inthe return duct work, or otherwise, either the permanent filter suppliedor a disposable filter may be used. If a disposable filter is used, the minimum area required is as follows:

MODELNO, FILTERAREA(MIN.)

PWC182 480 sq. in, PWC242 480 sq. in.

PWC302 480 sq. in.

THERMOSTAT

The roomthermostatshouldbe locatedonan insidewallwhereit willnot besubject todrafts, sun exposureor heat

fromelectrical fixtures or appliances. Followthemanufacturer's instructions enclosedwith thethermostat for general installationprocedures. Color codedinsulated wires (# !8 AWG)should be usedto connectthethermostat to the unit.

POWERANDCONTROLWIRING

ELECTRICALCONNECTIONS

ALL WIRINGSHOULDBEDONEIN ACCORDANCEWITHNATIONALELECTRICALCODE,ANSI/NFPANo. 70 (LATEST EDITION).IN CANADACSAC22.2 Part 1 (LATESTEDITION),ORWITH LOCALCODES,WHERETHEYPREVAIL:

Usewiringwithatemperaturelimitationof75°C rain. Runthe 208or 230 volt,60hertzelectric powersupplythrough a fused disconnectswitch to thecontrolboxof the unit andconnectas showninthe wiringdiagramlocatedon the in- side ofthe control access panel.

The unitmust beelectricallygrounded in accordancewithlocal codesor in theabsenceof localcodeswiththe Na-

tional Electric CodeANSI/NFPA No. 70 (latest edition)or CSAC22.2 Part 1 (latest edition).

Powersupplyto the unit must be N.E.C. Class1, and mustcomplywith all applicable codes.A fused disconnect switch should be field providedfor the unit. Theswitchmust be separatefrom all othercircuits. If any of the wire supplied with the unit must be replaced, replacementwire must be of the type shown onthe wiringdiagram.

Electricalwiringmust be sized tominimumcircuitampacitymarked on theunit. USECOPPERCONDUCTORSONLY. Eachunit must bewiredwith a separatebranchcircuitand be properlyfused.

SEQUENCEOFUNIT OPERATION

COOLING- Whenthe thermostatis inthe coolingmode,the 0 circuitis poweredwhichenergizesthereversing valve. Uponcoolingdemand,the thermostat closescircuitRto YandG. ClosingRtoY closesthe unit contactor,startingthe compressorandoutdoorfan. Thethermostatautomatically closesRtoGcircuitwhichalsobrings ontheindoor blower

atthe sametime. Uponsatisfying coolingdemand,the thermostatwill opentheabovecircuitsand openthe main con- tactor, stoppingthe compressorandoutdoorfan. If theunit is equippedwith a time delay, the blower will coritinueto operatefor 90 seconds whichimprovessystemefficiency.

HEATING- Uponheating demand the thermostatclosescircuitRto Y closingthe unit contactor,starting the com- pressor andoutdoorfan. Thereversingvalveis.no.t-energizedin the heating mode.Thethermostatagainautomatical- ly brings on the indoorblowerat the sametime. Thesecondstage of thethermostatclosescircuftRto W closingthe unit sequencers, bring theauxiliary electric heaton. Uponsatisfying heating demandthe thermostatopensabovecir-

cuitsand stops unit operation.

DEFROSTCYCLE- if outdoor ambient conditions are such that frost forms on the outdoorcoil,the defrost control monitorsthe need for andinitiatesandterminates defrost cycles as neccessary tomaintain systemperformance. The defrost controlis time/temperature initiated and temperatureterminatedwith a maximum defrost time (time-out) of

10 minutes. Timebetweendefrost cycles is pre-set at 60 minute intervals at the factory, but can be field adjusted to 30, 80, or 90 minutes. Seeillustralion for field adjustment of defrost timing. For best performancein RegionIV, the PWC242defrost interval should be adjusted to 30 minutes.

PA,T,O.I ,tt,,O0,,( [ l SUPERSEOESI NEW l PAGE OFtO

The defrost controlwill initiatea defrosl cycle if the time period haselapsedand the defrost sensordetects a temperature below freezfng. At the slart of the defrost cycle, Ihe defrost ControlwUIenergize the reversing valve

solenoid,shift(ng the reversing valve and de-energizingthe outdoor fan. The defrost reraywilt alsoclose, energizing auxiliary heat for increasedcomfortduring defrost. Theunit will remain in thedefrost modeuntil the defrost sensor

hasdetermined that lhe frost has been removedfrom the coil or a 10 minute timeperiodhas elapsed.

FIGURE3

OEFROST

TEST PINS

OEFROST

TIMEJUMPER

T1 = 30 MINUTES

T2 = 60 MINUTES T3 = 90 MINUTES

Thedefrost controlis alsoequippedwitha setof testpinstoaidintroubleshootingofthedefrost system.Thefollow-

ing is a briefoutline of the testing of the defrost system.

Thedefrostsensorwilt be closedat 32° F or below.If temperaturesaresuchthat theswitchis notclosed,jumper

between the defrostsensorterminalson the defrostcontrol.

Start the systemin heating operation.

Jumper testpins. A 1/4" quick connectterminalcrimpedontoa solidwireor brazing rod workswellfor testjumper.

Closing test pins speedup time intervalby a factor of 256.

DEFROSTCONTROLSETTINGDEFROSTTESTCYCLETIME

T1-30 minutes 7 seconds T2-60 minutes 14 seconds

T3-90 minutes 21 seconds

Afterclosingtest pinsand appropriatecycletimehaselapsed,the reversingvalveshouldshiftto defrostmodeand

theoutdoor fan should stop. Aftertwosecondsof defrostoperation, the reversing valveshouldshift back to heating

operation and the outdoor fan shouldstart.

SYSTEMPERFORMANCE

For maximumperformanceof this heatpumpsystem,theoperatingtemperaturesand pressureshouldbechecked

and superheat determined at StandardARItestconditionsof 82°F outdoor- 80°F indoordry bulb/67°F wet burb. If

the superheatmeasureddeviatesfrom thevalues in thetablebelow,therefrigerant chargeshouldbe adjustedaccor-

dinglyfor maximum performance.

PWCSUCTIONSUPERHEAT -TABLE2

OutdoorUnit Model

PWC182

PWC242

SuctionSuperheat@ A.R.I. Conditions

18° . 20OF 17° - 19%

[

PARTNOI 4t_g4DOg4I DATE] 4iS-g,I SUPERSEOESI NEWI RAGE8OF_O

MAINTENANCE

NORMALMAINTENANCE

WARNING: PRIORTO ANY OF THE FOLLOWING MAINTENANCE PROCEDURESSHUT OFF ALL ELECTRICALPOWERTO THE UNIT. FAILTURETO DOSOCOULDCAUSEPERSONALIN- JURY.

Periodic inspectionand maintenancenormallyconsistsof changing or cleaningfilters and (under someconditions)

cleaning the coils.

FILTER- supplied. Inspectonceamonth.Replacedisposable,or clean permanenttypeasnecessary. DONOTreplace

permanenttypewith disposable.

MOTORS- indoorand outdoortan motors are permanentlylubricatedand requirenomaintenance.

OUTDOORCOIL- Foreignmaterialshouldnot beallowedtoaccumulateontheoutdoor coilsurfaceor otherpartsinthe

air circuit. Cleaningshould beasoftenas necessaryto keepthe coil clean. Usea brush,vacuumcleanerattachment, or other suitable means. If wateris used to cleanthecoil, be sure power to the unit is shutoff prior tocleaning.

NOTE:CARESHOULDBE USEDWHENCLEANINGTHE COILSSOTHATTHE COILFINSARENOTDAMAGED.

OUTDOORBASEDRAIN- Foreignmaterial shouldnotbeallowedtoclogthe drain hole.Inspectandclear'drain open-

ingprior to heatingseason.

PHYSICALANDELECTRICALDATA

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CONNECTION DIAGRAM

I PAGE10 OF 10

1PA'_RT N0. I 411941)094 I DATE I 4-15-94 I SUPERSEDES I NEW

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,.)NNECT I ON DIAGRAM

PWC

SELF CONTAINED

THRU-THE-WALL HEAT PUMP

Part No. 30790F08g Date 6-1-69

Supersedes 30790G082 Page_of 12

Installation and

Maintenance Instructions

_O,MSTP_,

Part N_ 30790F089

$upereedes 30790G082

Date. 6-1-89

Page2__2__of 12

FORWARD

This is a self-contained heat pump designed for Installation through an exterior wall. The unit is Underwriters' Laboratories listed under heat pumps and is in compliance with Underwriters Standard, UL 559.

The unit is also certified to the Air Conditioning and Refrigeration Institute as complying to ARI Standard 240. To simplify the proper Installation and to assure that the unit will operate tn conformity with general ac-

cepted safety regulations, you should read carefully the instructions outlined In this manual. Failure to comply with the Installation Instructions, Operating Instructions or Maintenance Instructions, or Alterations of internal widng or parts not specifically outlined within this manual will void the Agency Listing's

and Manufacturer's limited warranty.

KEEP THIS MANUAL IN A SAFE PLACE FOR READY REFERENCE.

PartNo. 307SOF089 Supersedes 30790G082

Date 6-1-89

Page _of 12

INTRODUCTION

This manual is intended to familiarize the installer, serviceman, and the user with the installation, operation

and maintenance of this thru-the-wall heat pump. This unit is shipped from the factory in one package completely assemblied and wired. A specially designed

trap assembly is shipped, secured to the air return area in lower front of unit. Check the rating plate to confirm heating and cooling capacities are as ordered and are as shown on the

packaging label.

When this unit is unpacked, a check should be made for any damage. If any damages are discovered, DO

NOT INSTALL THE UNIT. Notify the transportation company and make proper notation on the carders freiaht bill. Damage claims must be filed with the carrier at once.

The manufacturer can assume no responsibility for damages which Occur in transit or for improper Opera- tion of the unit as a result of shipping damages.

Part No. 30?90F089 Date 6-149

Supersedes 30790G082 ,, Page _of 12

TABLE OF CONTENTS "

Page

INSTALLATION

Site Preparation ............................ 5

Condensate and Defrost Drain ................. 6

Electrical Connections ........................ 7-8

Thermostat ............................... 9

Air Filter ......... ; ...................... 9

Duct Work ............................... 9

Unit Checkout Procedure ..................... 10

OPERATION INSTRUCTIONS

Heating Operation .......................... 11

Cooling Operation .......................... 11

System Shutdown .......................... 11

MAINTENANCE AND SERVICE

Air Filter ................................. 12

Chassis Removal ........................... 12

Part No. 307g0F089

Supersedes 30790G082

Date. 6-1-89

Page_of 12

INSTALLATION

Site Preparation

Tills unit is approved for thru-the.wall installation, with zero clearance to combustible material. The unit must

be installed within a conditioned space to prevent freezing of defrost water in trap assembly and to avoid jacket heat loss and surface condensation problem.

This unit must be installed with the wall sleeve specified for this unit. Refer to the manufacture's specifica- tion sheet for complete information and demensions.

Assemble the wall sleeve in accordance with the instructions furnished with each wall sleeve. Install the wall sleeve level and square in all comers. It is to extend a minimum of 114" to 3/8" maximum

beyond finished wall to permit caulking all around the sleeve without blocking drain holes at bottom front of sleeve.

Before installing unit, Inspect wall sleeve. Make sure the gaskets located on the inside of the outer flanges are firmly attached to the sleeve and are not damaged. Damage or loose gaskets must be repaired before installing unit.

The sleeve is not intended as the sole support for the thru-the-wail unit. An additional support must be pro- vided beneath the front of the unit for adequate support, The use of vibration insulation matedai between the unit and the support is recommended. See Figure 1.

Wall Sleeve • Seal space between wall sleeve and building opening using non-hardening caulking com-

pound. The seal must be water tight+

g"x 22" rain. opening to align with return air opening in unit.

Hole for drain. Ddll hole on left

or dgtht side

• through base after unit is installed.

FIGURE 1.

Celotex, or equivalent

Plywood

Part No. 30790F089 Date 6-1-89

Supersedes 30790G082 Page_of 12

INSTALLATION

Before sliding unit into sleeve, remove 5 screws and washers from top panel. Slide unit into sleeve until the

angle on top of the unit lines up with the top flange of the sleeve, and should almost touch. Fasten unit to sleeve with the 5 screws and washers above.

Condensate and Defrost Drain The condensate drain trap furnished with the unit is a copper tube assembly and is furnished with three

pieces of plastic tubing. To install condensate drain (Reference Figure 2.), connect one of the plastic tube ends over the 5/8" O.D.

fitting welded to the center of indoor condensate drain pan and another end to.the 5/8" O.D.fitting on the chassis base. Connect the third plastic tube end to the open drain trap,

The drain line should pitch gradually downward at least 1 inch per foot of horizontal run to open drain trap.

Be certain that plastic drain tube has free drainage and Is not cdmpad or flattened at any bend. Test drainage by pouring water into drain pan under indoor coil and see that It Is removed rapidly through the drain tubing.

The plastic drain connection Is provided so that tt may be disconnected from the permanent drain tubing in the building without unsoldering tn the event It becomes nceccesaary to remove the refrigeration drawer

assembly. TOTAL DEFROST DRAIN SYSTEM MUST BE LOCATED IN THE CONDITIONED AREA TO AVOID

FREEZING.

FIGURE 2.

Drain line must not

be above lowest drain pan fitting.

i,ii_ II •

r-w

Indoor coil Drain pan

Chassis base

Use hole provided

on either side of base to exit unit.

Retum air duct (if used)

5/8" rain. O.D. copper or alum. drain tube

(shaded Item. Pitch 1 In. per ft. Installer supplied)

One 5/8" O.D. copper trap & plastic tubes (3) (furnished)

Alternate route through

return air duct.

Open drain trap in conditioned

space to prevent freezing and

damage.

PanNo. 307g0F089 Supemedes 30790G082

Date 6-1_9

Page T of 12

INSTALLATION

Electrical Connections All wiring to unit must comply with the national Electrical Code NFPA No. 70 or local codes, where they prevail.

ANY ALTERNATION OF INTERNAL WIRING CAN VOID UNDERWRITER'S APPROVAL, ARI CER- TIFICATION AND MANUFACTURE'S LIMITED WARRANTY.

The series and rating plates indicate the operating voltages, phase, ampacities and maximum fuse size and electric heater ratings. Units must never be installed where voltage exceeds 110% of higher voltage indicated on rating plate, or less than the minimum operating voltage on rating plate,

Ratings and BTU output are based on 230 V, 60 HZ supply. Voltages other than this rated voltage will alter the BTU output of this unit. For specific ratings at voltages or frequencies other than that designated con- tact your distributor or the manufacture.

FAILURE OF THE COMPRESSOR AS A RESULT OF OPERATION ON IMPROPER VOLTAGE VOIDS THE COMPRESSOR REPLACEMENT WARRANTY.

Multiple power supply connections must be used when total unit amp draw Is over 48 amps. If multiple power supply connections are used, separate fused disconnects must be Installed for each circuit between the

main panel and the supply terminals In the unit. Circuit No. 1, terminals L1 and L2 on the terminal block Is always used to supply power to the heat pump

section. See Figure 3, 4, and 5. Circuit No. 2, terminals L3 and L4 on terminal block (units up to 11.0 KW) or fuse block (units over 11.0

is always used to supply power to electdc heaters. Single entry supply may be used on units, when total amp draw, (heat pump plus heaters) Is less then 48

amps, and is not In violation of prevailing electrical codes. Units with 7.2 KW heaters or less are supplied with Internal jumpers between 1.1& 1.3, and L2 & L4 for single

entry supply. Remove jumpers between L1 & I..3and 1.2 & L4 when multiple entry supply is to be used. Fuse and wire sizing must be in accordance with prevailing electrical codes. See Product Specification sheets

or Unit Sedes and Rating Plate for ampacities end maximum fuse.

Part No. 30790F089

Supersedes 30790G082

Date 6-1-89

Page_ of 12

FIGURE 3.

SINGLE ENTRY SUPPLY

[]

208-230 voit

1 Ph. power supply

I I

Remove internal for multiple entry Supply.

PWC18E4.8, PWGI8E7.2

PWC24E4.8, PWC24E7.2

208-230V

1 Ph. power supply

t-_ Circuit I"_

ICircuit

I No.I No.2 I

FIGURE 4,

MULTIPLE ENTRY

SUPPLY

PWC18E9.2, PWC18E10.7

PWC24Eg.2, PVVC24ElO.7

r I Circuit

! No.1

208.230V

1 Ph power supply

Circuit

No. 2

FIGURE 5.

MULTIPLE ENTRY

SUPPLY

PWC18E14.7

PWC24E14.7

Part No. 30790F089 Date 6-1-89 Supersedes 30790G082 Page_of 12

Thermostat

This unit requires special thermostat for operation. See product specification sheets or label on unit for manufacture's part number. Install the thermostat according to directions furnished with It. Select a loca- tion in a room having the most wall or window area exposed to the outsid_ Locate on an inside wall, away from drafts, sunlight or any heat producing appliances. Connect thermostat wires to pigtail leads on unit with wire nuts following wire diagrams attached to unit.

Air Filter This unit is supplied with a permanent type high filtration filter, located in front of the indoor coil. If an In-

tallation is made in which it Is more desirable to mount the filter extedor to the unit In the return duct, the

permanent filter supplied can be used or a disposable filter may be used. If a different filter or filters are used the minimum total filter area required is 375 eq. in. of nominal 112inch thick media, if a remote filter

is Installed, the permanent filter supplied with this unit must be removed.

Duct Work Provide duct work sufficiently large enough to handle the air volume at the total external static pressure

not exceeding the rating of the unit published in the Product Specification sheet for the rated cooling air volume.

Connect supply duct to top of unit using canvas connections or other flexible connection to prevent sound transmission Into the duct system.

To connect the return duct to the unit, use e straight piece of duct 21 _" by 9".

Insert duct into return opening in bottom of unit and flange duct over existing flanges around opening In- side unit. Make sure that all sides of the duct are flanged over to permit removal of cooling chassis If re- quired. Use a flexible connection to attach remainder of return air duct.

Adjustments No adjustments are required or should be attempted regarding any of the components of the heat pump

chassis and supplementary electdc heaters.

The unit should be checked to see that none of the wiring is loose or missing. The plug-in electrical connec.

tors between the cooling chassis and the main control compartment should be checked to make sure the plugs are firmly seated and none of the wires are loose.

Part No. 30790F089

Supersedes 30790G082

Date 6-1-89

Page 10 of 12

INSTALLATION

A. Unit Check-Out Procedure - IMPORTANT

1. Filter(s) must be clean and in place as to filter all air passing over

2. Set thermostat to "OFF" position.

3. Check that correct size fuses are installed for unit.

4. All panels must be in place.

5. Turn on main power to unit.

indoor coil,

B. Heating Check

1. Set fan switch to "AUTO".

2. Set thermostat lever to lowest temperatuf'e.

3. Set thermostat switch to "HEAT" position (if indoor ambient temperature is near or colder

than thermostat setting, heat pump will start immediately).

4. Slowly adjust thermostat to warmer temperature until first stage heat is activated (com- pressor will start).

5. If'possible, check outdoor fan to make sure it's rotating (this is especially important If heat

pump has been installed for sometime and not running in the winter such that the outdoor fan plenum could be clogged with snow or ice build-up).

6. Check indoor air outlet to verify indoor fan is blowing air and getting warmer.

7. Adjust thermostat lever to at least 5"F warmer temperature So that second stage heat will

activate.

8. Check indoor air outlet for increased heating (higher temperature).

C. Cooling Check

1. Set thermostat switch, to "OFF" position for minimum of 5 minutes to allow heat pump

pressures to equalize.

2. Set thermostat lever to lowest temperature for cooling

3. Set thermostat switch to "COOl." position (compressor should start unless indoor ambient

is near or colder than thermostat setting).

D. Blower Operation

1. Set thermostat switch to "OFF" position.

2. Set fan switch to "ON". Indoor fan only will operate.

3. Return fan switch to "AUTO". Indoor fan will stop.

Part No. 30790F089

Supersedes 30790G082

Date. 6-1-89

Page 11 of 12

OPERATION INSTRUCTIONS

The following instructions are to be followed to obtain years of trouble free operation of your year-around comfort system.

To start unit turn on main power (may have two disconnect switches). If the outdoor temperature is below

indoor temperature, the main power should be turned on 24 hours before starting unit in order to assure no liquid refrigerant is in the compressor crankcase, and to prevent valve damage of compressor.

Operation of this unit is automatic and will provide heating or cooling depending on the setting of the thermostat.

Heating Operation

1. Set thermostat system switch to "HEAT;',

2. Set thermostat lever to desired temperature.

3. Set fan switch to "ON" for continuous indoor blower operation or to "AUTO" for indoor

blower to cycle corresponding with thermostat cycling.

Cooling Operation

1. Set thermostat system switch to "COOU'.

2. Set thermostat lever to desired temperature.

3. Set fan switch to "ON" for continuous indoor blower operation or to "AUTO" for indoor

blower to cycle corresponding with thermostat cycling,

System Shutdown

1. For temporary or short periods of shut.down, set thermostat system to 'OFF" and fan switch to "AUTO".

2. For a prolonged period of shut-down, set thermostat system switch to "OFF" and fan switch to "AUTO". Tum off electdc power supply. (Two disconnect switches may supply unit.)

Part No. 30790F089

Supersedes 30790G082

Date, 6-1o89

Page 11 of 12

OPERATION INSTRUCTIONS

The following instructions are to be followed to obtain years of trouble free operation of your year-around comfort system.

To start unit turn on main power (may have two disconnect switches). If the outdoor temperature is below

Operation of this unit is automatic and will provide heating or cooling depending on the setting of the thermostat.

Heating Operation

1. Set thermostat system switch to "HEAT".

2. Set thermostat lever to desired temperature.

3. Set fan switch to "ON" for continuous indoor blower operation or to "AUTO" for indoor

blower to cycle corresponding with thermostat cycling.

Cooling Operation

1. Set thermostat system switch to "(_OOU'.

2. Set thermostat lever to desired temperature.

3. Set fan switch to "ON" for continuous indoor blower operation or to "AUTO" for indoor

blower to cycle corresponding with thermostat cycling.

System Shutdown

1. For temporary or short periods of shut-down, set thermostat system to 'OFF" and fan

switch to "AUTO".

2. For a prolonged period of shut-down, set thermostat system switch to "OFF" and fan switch to "AUTO". Turn off electric power supply. (Two disconnect switches may supply unit.)

Lennox PWC183, PWC18E4.8, PWC18E9.2, PWC242, PWC18E10.7 Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual